Design and method of molding the same



Jan. 1, 1929. 1,697,182

c. J. HALL ET AL DESIGN AND METHOD OF MOLDING THE SAME Filed Oct. 4,1924 PRINT /1 WITNESSES: INVENTOR Char/es J. Ha/l, M, a d Geoye61/49/77? ATTORNEY Patented Jan. 1, 1929.

UNITED STATES.-

PATENT OFFICE,

I CHARLES J HALL, OF WILKINSBURG, AND GEORGE C. KENT, OF TURTLE CREEK,PENN- SYLVANIA, ASSIGNORS T WESTINGHOUSE ELECTRIG AND MANUFACTURING COMrm, ACORPOBATION or PENNSYLVANIA.

. DESIGN AND EETHOD OF MOLDING THE SAME.

Application filed. October 4, 1924. Serial No. 741,620,

Our invention relates to molded articles and has particular reference toa method of.

producing a print or a design in molded material. 7 The principal objectof our invention is, therefore, to produce a design, in a molded articlewhich is impregnated with a heathardened binder.

Another object of our invention is to pro 0 vide a method of moldin adesign in a lam-.

inated, impregnated artlcle and of producing a design of uniform color.

Heretofore, designs have been molded in material impregnated with aheat-hardened 5 binder, such as a phenolic condensation product, byplacing a sheet of paper upon which the desi n is printed between sheetsof impregnated tissue paper and molding with heat and pressure. Thismethod is satisfactory for most purposes, but the background of theprint produced thereby is dark colored and where considerable contrastbetween the design andthe background is desired this method is notsatisfactory. \Vhen 5 using this method on thin molded articles,

the print is apt to break apart in molding. This is especially truewhere a slight flowing action or readjustment of the body of thematerial occurs in molding.

I Our invention is an improvement on the above process. Instead ofdisposing the print between sheets of thin absorbent paper, we employ aplurality of sheets of various kinds, which are so treated that we areable to mold a print in the surface of the article without effectingdistortion or discoloration thereof.

In the drawing constituting a parthcreof and in which like numeralsdesignate a like parts;

Figure 1 is an exploded View in perspective of the layers of materialcomprising the article before molding,

Figure 2 is a plan view of the molded article showing the print thereon,and

Fig. 3 is a side view of the molded article, partially in'section.

The body 1 or main'portion of-the article comprises a plurality oflayers of fibrous material such as impregnated paper or duck.

Upon the body 1 we p ace two sheets of impregnated cambric 2 which maybe of any desired color but preferably of a light color and over this isplaced a sheet of unimpreg nated parchmentized paper 3 such as fishpaper. The cambric provides a strong backing for the design and isimpregnated with a bmder such as a phenolic condensation product to suchan extent that it provides ust the correct amount of binder to properlyconsolidate the fish paper. The fish paper being parchmentized preventsan excess of binder from the backing sheets 1 or from the cambric 2 fromflowing therethrough and discoloring the outer layers of the paper whensubjected to heat and pressure. The

design which is printed on unimpregnated calendered paper 4 is placedover the fish paper 3 and-a sheet of impregnated paper 5, such as appaper or tissue paper is placed on the outer surface. The amount ofbinder in the pp paper is just suflicient to consolidate sheets 3, 4 and5 when subjected to heat and pressure and provides a clear transparentsurface without causing any discoloration or cloudingof the print 4.

Our invention provides a molded article comprising impregnated andunimpregnated fibrous material. When the article is consolidated withheat and pressure, it provides a structure, which may be used as a. nameplate or a design as molded. The design or print may be molded in thesurface of a thin plate and attached to another article with screws orother suitable means; or the design may be molded in the surface of amolded article comp-rising non-laminated or impegna-ted sheets oflaminated material.

Although we have described a specific embodiment of our invention we donot wish to be limited thereto .as other modifications of our inventionwill suggest themselves to those skilled in the art without departingfrom. the spirit of our invention. For example we may substitute otherforms of impervious paper for the fish paper of layer 3.

We claim as our invention:

1. The method of molding designs which comprises superimposingimpregnated fabric on a body portion of impregnated molding material,placing a sheet of parchmentized paper thereon, disposing a-printbetween said paper and a sheet of transparent impregnated paper andcuring with heat and pressure.

2. The method of molding designs which comprises superimposingimpregnated cambetween sai Mia on the body portion of impregnatedmolding material, acing a sheet ofparchmentized pa er thereon, disposinga print paper and a sheet of transarent impregnated paper and curingwith lieat and pressure.

3. The method of molding designs in the body of impregnated materialwhich comprises plac ng. an im regnated fabric of ight color on said boy, placing thereon a design printed on unimpregnated calendered paperand disposed between a sheet of parchmentized paper and a sheet oftransparent impregnated paper and curing with heat and pressure.

4. The method of molding desigrisin a.

' body of impregnated material which comprises placing an im regnatedfabric of light color on said b0 y, placing thereon a design printed onunimpregnated calendered paper and disposed between a sheet ofunimpregnated parchmenti zed paper and a sheet of transparent imregnated paper and curing with heat an ressure.

5. The methodo molding designs in a body of impregnated material whichcomprises lacing an im regnated fabric of Y light co or on said he y,placing thereon a design printed on unimpregnated calendered paper and Idisposed between a sheet of parchmentized paper and a sheet of thintransparent impregnated paper and curing with heat and pressure.

6. A method of molding which comprises twecn and a transparent coveringlayer on' said design.

9. A molded design comprising an ornamented design, a backing ofmaterial of light color therefor, a layer of impervious materialinterposed thcrebetwcen and a transparent covering layer on said design.

'10. A molded design comprising an ornamented design, a backing offabric of light color therefor, a layer of impervious materialinterposed therebetween and a transparent covering layer on said design.

In testimony whereof, we have hereunto subscribed our names this firstday of October, 1924.

CHARLES J. HALL. GEORGE o. KENT.

